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    Cascade Control 1

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    Didik Riswanto
    This document discusses cascade control systems which use two or more control loops connected in series to control a single process variable. The inner loop, or secondary loop, must respond much faster than the outer or primary loop. The primary loop controller adjusts the setpoint of the secondary loop controller. It is important to first tune the faster secondary loop and then tune the primary loop. Proper connection of the control system analysis tool is discussed to record signals from both loops. Anti-reset windup protection is also needed to prevent integrator windup between the primary and secondary controllers.

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    Cascade Control 1

    Uploaded by

    Didik Riswanto
    140 views4 pages
    This document discusses cascade control systems which use two or more control loops connected in series to control a single process variable. The inner loop, or secondary loop, must respond much faster than the outer or primary loop. The primary loop controller adjusts the setpoint of the secondary loop controller. It is important to first tune the faster secondary loop and then tune the primary loop. Proper connection of the control system analysis tool is discussed to record signals from both loops. Anti-reset windup protection is also needed to prevent integrator windup between the primary and secondary controllers.

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    This document discusses cascade control systems which use two or more control loops connected in series to control a single process variable. The inner loop, or secondary loop, must respond much faster than the outer or primary loop. The primary loop controller adjusts the setpoint of the secondary loop controller. It is important to first tune the faster secondary loop and then tune the primary loop. Proper connection of the control system analysis tool is discussed to record signals from both loops. Anti-reset windup protection is also needed to prevent integrator windup between the primary and secondary controllers.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    140 views4 pages

    Cascade Control 1

    Uploaded by

    Didik Riswanto
    This document discusses cascade control systems which use two or more control loops connected in series to control a single process variable. The inner loop, or secondary loop, must respond much faster than the outer or primary loop. The primary loop controller adjusts the setpoint of the secondary loop controller. It is important to first tune the faster secondary loop and then tune the primary loop. Proper connection of the control system analysis tool is discussed to record signals from both loops. Anti-reset windup protection is also needed to prevent integrator windup between the primary and secondary controllers.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 4

    CHAPTER

    7 Cascade Control
    Control System Analysis Test Procedure
    By definition, cascade control systems consist of two or more control loops in series. Cascade loops are invariably installed to prevent outside disturbances from entering the process, and to put the principle nonlinearities in a much faster responding inner loop controller. The primary loop controller adjusts the secondary loops controller setpoint. A cascade control system controls a single variable, and the inner loop controller is used only to assist in achieving this. In order for cascade control to be successful, the secondary loop dynamic response must be much faster than the primary loop. A good rule of thumb is that the primary loop should be three times slower than the secondary. Otherwise, the primary loop will need to be de-tuned to such a degree that cascade control will degrade the overall quality. The following example illustrates a typical cascade system to control a heat exchanger.
    Protuner 1600PC

    Test 2 -Primary with Secondary in Auto RSP PV1 FT 1 PD2 FIC PD1 Test 1 Secondary

    TIC

    PV2

    Coolant Flow = Fc

    FT 2

    TT 1

    TT 2

    Process Fluid Flow = Fp

    Figure 7.1 - Preferred Protuner Connection to Test Cascade Control Loops

    Application Manual

    69

    CASCADE CONTROL

    The preferred Protunertm connection to test loops configured in cascade, is to record the controller output (PD signal) and process variable (PV signal) of both the primary and the secondary controllers as illustrated in Figure 7.1. In many DCS systems, the PD signal from the primary controller, which is the remote setpoint (RSP) to the secondary controller is in software and not available as an analog signal. One solution, is to program the DCS system to retransmit the controller output (PD) signal as an analog signal to a spare output point. If for some reason, it is not possible to connect the Protunertm to record the PD signal of the primary controller, an alternate connection diagram is illustrated in Figure 7.2.

    Protuner 1600PC

    FIC TIC
    Note: No connection point for PD2 is present. When analyzing TIC step test results use data PV1 in place of PD2

    PV1

    PD1

    PV2

    FT 1

    Test 1 Secondary

    Coolant Flow = Fc

    FT 2

    TT 1

    TT 2

    Process Fluid Flow = Fp

    Figure 7.2 - Alternate Protuner Connection to Test Cascade Control Loops

    As illustrated in Figure 7.2, the alternate Protunertm connection to test cascade control loops is to simply record the three available signals.

    Application Manual

    70

    CASCADE CONTROL

    Control System Analysis Test Procedure

    Regardless of the connection type used, the Control System Analysis procedure to test and optimize the closed loop operation of a cascade control system is the same. The following outlines the proper procedure: Test and tune the secondary control loop first. 1. The secondary control loop in this example, is the flow control loop. Follow the test and analysis procedures in Chapter 3. Enter the Protunertm tuning parameters in the secondary and place the loop back in automatic in remote setpoint mode. Next test and tune the primary controller.

    2.

    The primary loop in this example is the temperature control loop. If the Protunertm is connected using the alternate cascade connection as shown in Figure 7.2, you will need to select the signals for analysis as shown: Process Demand Signal: FIC-PV (In the alternate connection, TIC-PD was not recorded.) Process Variable Signal: TIC-PV
    Table 7.1 - Signal Analysis

    Protection Against Windup


    In a single loop controller, reset windup or integrator saturation can occur if the output saturates and the controller continues to integrate the error. That is, if the controller output reaches 100% and the valve is fully open, or if there is an output limit on the controller and the controller continues to integrate the error. In these cases, the integrator portion of the PID calculation can calculate some very large values for the controller output, even though the actual controller output is limited. If this happens, it can take sometime for the calculated controller output to get back to an actual controller output value again, this can result in a very large overshoot. To prevent this, the controller PID algorithm must be written to automatically stop the calculation of the controller integral action when an output limit is reached. Most single loop PID controller algorithms incorporate some form of anti-reset windup protection.

    Application Manual

    71

    CASCADE CONTROL

    In cascade control loops, reset windup or integrator saturation can occur if the output of the secondary controller saturates and the primary controller continues to integrate the error. To prevent this, it is necessary to employ external anti-reset windup protection to automatically stop the calculation of the primary controller integral action when an output limit is reached on the secondary controller. In most DCS systems, cascade controllers have external anti-reset windup protection as part of the normal cascade control loop configuration. We have found in actual field testing, that when single loop controllers are configured for cascade control, external anti-reset windup protection is not setup properly, Thus, large overshoots occur during startup in response to large setpoint changes, and following large load disturbances, which could be prevented.

    Application Manual

    72

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